Switch



Jul 31, 1951 R, Po-PP 2,562,390

Filed Feb. 11,, 1949 2 Sheets-Sheet 1 INVENTOR. RuaQJ/f .POp Q R. POPP SWITCH Jul 31, 1951 2 Sheets-Sheet 2 Filed Feb. 11. 1949 INVENTOR. Zzzaalf P Patented July 31, 1951 SWITCH Rudolf Popp, Valparaiso. Ind., assignor to McGill Manufacturing Company, Inc., Valparaiso, Ind.. a corporation of Indiana Application February 11, 1949, Serial No. 75,799

This invention relates to an improvement in switches of the type in which stationary and movable contact devices are mounted betweenand supported by a pair of flat insulating members I Claims. (Cl. 200-168) 2 provements without materially increasing the cost of the switch and without reducing its capacity.

A featureof the invention is the assembly of maintained in substantially parallel relation and 5 a molded plastic switch housing and metal terthis preassembly is mounted in a removable cover minals in which the housing comprises two idenhousing. An example of such a switch, used very tical mating members having substantially flat extensively in the electrical trade, is disclosed configurations with flanged edge portions definin United States Letters Patent No. 1,974,054 ising a hollow within the housing for receiving the sued to Rudolf Popp on September 18, 1934. conductive, current-carrying parts of the switch,

In constructing these prior switches, it is cussaid housing members being a part of the switch tomary to make each stationary contact device proper and serving to support. enclose and comin the form of a leaf spring anchored to a flat pletely insulate these current-carrying parts of terminal piece. The spring engages the movable the switch ascontrasted with the prior-identicontact device, and in so doing, it exerts a thrust fled switches wherein the housing is removable upon its terminal piece. For retaining the termiand serves merely as a shield for encasing the nal pieces securely in position, resort is had to switch proper. lugs or projections on these terminal pieces which Another feature is the provision of H-shaped extend through corresponding apertures in the projections on the inside surfaces of the housing flat insulating members, these projections being parts for engaging and supporting the terminals clinched or upset to make the structure mechanat their edges and holding the terminals in place ically secure. Inasmuch as the projections on within the aforesaid hollow when the switch is the terminal pieces are exposed through the apassembled. The terminals have I-shaped conertures in the insulating members, it is necessary figurations which are complementary to the H- to shield or encase the switch by an outer or shaped projections sothat the edges of the tercover housing in order to meet safety requireminals are engageable with these projections for ments. In most instances this practice is not proper mechanical support. while the terminals objectionable, but in some cases it has been found are insulated from any contact therewith outside that the outer switch housing cannot be acthe housing. commodated within the very limited space For a better understanding of the invention, which is available for installing the switch. reference may be had to the following detailed Hence, it is desirable to find some way of making description thereof taken in connection with the the assembled switch operating mechanism more accompanying drawings. wherein: shallow while providing a well insulated device Fig. 1 is an outside perspective view of a switch so that there is adequate protection against constructed in accordance with and embodying shock, short-circuit and like hazards. the principles f this inventifln;

An object of the invention is to provide an Fig. '2 is a plan view of the switch with one improved switch of the aforesaid character which half of the housing removed therefrom, certain is considerably more shallow than the commerparts being shown in section;

' cial embodiment of the above identified present 40 Fig. 3 is a partial side elevational view of the switch. switch;

Another object is to make the overall depth Fig. 4 is a cross section on the line 44 of of the improved switch with its housing) no Fig. 3; greater than the depth of the conventional switch Fig- 5 is a P V w ow one Of the two ith t it housing, identical parts of the switch housing;

Still another object is to support the metal Fig. 6 is a fragmentary, disassembled, perspecterminals and other conductive current-carrying tive view of the novel housing and terminal comparts of the switch entirely within a space or bination which is employed in the present switch hollow defined by two completely enclosing instructure; and sulating members. whereby no portion of the Fig. '7 is a disassembled perspective view of a terminals need be exposed through the insulating frame and nipple assembly used in the switch. members, and to do this within a space generally In practicing the invention, the switch housing the same as the preassembly of the prior switch is composed of two identical parts made from without its cover housing. molded plastic or other suitable insulation.

A further object is to make the foregoing im- These parts are substantially flat with flanged I edges adapted to meet for defining a hollow within the-housing to receive the electrical currentcarrying parts of the switch. A frame member, which is not electrically connected to the currentcarrying parts of the switch, supports the mounting nipple and the actuating means for the switch. The frame member is made unusually wide so that it, rather than the housing, bears the thrust of the mounting nut threaded on the nipple. This frame member has lugs which project through-apertures in the switch housing parts'a'nd are clinched to aid in securing the two parts of the housing together. A rotary contact device received in the aforesaid hollow is journaled in the housing by extending opposite ends of the stem or spindle thereof through registering holes in the two housing parts. A clip member is inserted through other registering apertures in the housing part and is clinched to hold the parts together.

The stationary contact devices that cooperate with the rotary contact device are completely shielded and supported by the housing. These terminals are approximately I-shaped and are disposed in the hollow within the housing. Substantially H-shaped retaining projections or bosses are provided on the inside surfaces of the housing parts to cooperate with the terminals. The bosses afford recesses for receiving and retaining the edge portions of the terminals with- 9 out the necessity of extending these edge portions through the housing parts for mechanical support. Consequently, there is provided a switch structure utilizing parallel insulating members to support the terminals but which differs from the conventional switch of this type in that the terminals are completely insulated from outside contact without using an outer shield for this purpose. Hence, the extra space normally occupied by such a shield is saved. The terminals are fo rmed with wings or nibs which are adapted to clinch the wires for making electrical connections thereto. The switch shown in Fig. 1 has a housing l0 made of molded insulating material such as plastic. This housing I0 is composed of two identical cup-shaped parts or insulating members i2 having fiat wall portions with flanged edge portions l4 that are adapted to mate for defining a hollow within the housing. The electrically conductive, current-carrying parts of the switch, to be described later, are disposed in this hollow. A threaded nipple or mounting stem l6 projects from one end of the switch and receives a mounting nut l8 by means of which the switch is secured to a suitable support such as the canopy of a light fixture. A universal lever 20 is rockably mounted on the outer end of the nipple l6. The switch is actuated by tilting the lever 20 in any desired direction on its seat or fulcrum in the well known manner. Customarily a ball chain 22 depends from the lever 20 so that the lever may be rocked downwardly by pulling on the chain.

As shown best in Figs. 2 and 7, the nipple I6 is secured to a U-shaped frame 24, the outer surface of which is flush with the front face of the insulated housing iii. A polygonal aperture 2i (Fig. 7) is provided in the bight portion of the frame 24 to receive a reduced collar portion 28 on the nipple It. In assembling the nipple I 6 on the frame 24, the collar portion 28 is inserted in the hole 26 and is upset as indicated in Fig.

- 2. so that the metal fills the corners of the hole 26. Thus, the nipple I6 is clinched to the frame 24 and is prevented from turning relative to this frame. The legs of the frame 24 are provided with lugs or projections 30, Fig. '7, that are received in small apertures 32, Figs. 2 and 5, formed in the housing members II. The frame 24 fits snugly in a rectangular aperture or recess 34 provided in the front or forward portion of each housing member l2. The parts of the lugs 30 which extend through the apertures 32 are clinched as shown in Fig. 1, thereby securing the frame 24 and housing members 12 together. The small apertures 32 merge with wider apertures 36 in the outer faces of=the housing members l2, enabling the lugs to be bent down beneath the outer faces of the housing "I.

The rear portions of the housing members l2 are held together by a clip 38, Figs. 2 and 3, which is inserted through suitable openings in the members i2 and is clinched, as shown in Fig. l. Recesses 40 in the outer faces of the members i2 afiord clearance for the clinched ends of the clip 38 so that these ends lie beneath the outer faces of the housing ill. The housing members l2 are held together by the lugs 30 and the clip 38, with the flanged edge portion I 4 of the members [2 being in contact on all sides of the housing in. If it is necessary to disassemble the switch, a screwdriver or other suitable tool is inserted in the apertures 38 and 40, and the lugs 30 and clinched ends of the clip 38 are straightened to permit separation of the housing members i2.

The switch is mounted in its position of use by first removing the nut [8, then inserting the nipple I 6 through a suitable aperture in a fixture canopy or other supporting wall (not shown), and the nut it then is replaced and tightened. The bight portion of the frame 24 is made sufilciently wide to bear substantially the entire thrust of the mounting nut l8, so that the plastic housing I0 is not subjected to any stress. As mentioned previously, the outer face of this bight portion is fiush with the front face of the housing ill, or if desired, it can protrude slightly ahead of the housing It to insure that the housin l0 does not contact the supporting wall with any pressure.

A well known form of rotary contact device and actuating mechanism therefore, fully disclosed in the aforesaid Popp patent, is employed in the present switch. This contact device, best shown in Figs. 2 and 4, comprises a spindle 42, ratchet wheel 44 and a bridging contact member 46. The spindle 42 and ratchet wheel 44 preferably are formed as an integral piece out of plastic insulating material. The ends of the spindle 42 are journaled in bearing holes 48 (Fig. 5) afforded in the housing members l2. The bridging contact member 46 consists of a star wheel, preferably made of fiber insulating material, and metallic contact pieces electrically connected to one another which are disposed on alternate teeth of the star wheel. The contact member 48 rotates with the spindle 42 and ratchet wheel 44.

A U-shaped pawl 44 cooperates with the ratchet wheel 44. The legs of the pawl 48 straddle the ratchet wheel 44, and the bight portion of this pawl is connected by a link 50 to a connector 52 (Fig. 2) in the lever 20, which connector receives an end of the ball chain 22. A coiled spring 54 interposed between the nipple l6 and the bight portion of the pawl 48 tends to urge the pawl 44 rearwardly and maintain the universal lever 20 seated on its fulcrum afforded by an annular groove in the outer end of the nipple It.

When the lever 24 is rocked on its fulcrum, the

pawl 48 is pulled forwardly, causing the hooked end of one leg of this pawl to engage a tooth of the ratchet wheel 44 and turn the wheel 44 a step clockwise, as viewed in Fig. 2. The other leg of the pawl 48 serves as a balancing and guiding leg. To further assist in guiding the pawl 48, there-are lugs or projections 58, Figs. 2 and 5, integral with the housing members I2 which embrace the pawl 48 near the bight portion thereof. Ordinarily this guiding function is performed by the legs of the U-shaped frame 24, but in the present instance this frame 24 has been made wider for the purpose mentioned above, so that its legs are considerably farther apart than the legs of the pawl 48. The bridging contact member 48 moves with the ratchet wheel 44, causing one pair of teeth on the member 48 to become disengaged from the stationary contact springs 58 and bringing a successive pair of teeth respectively into engagement with the springs. The contact springs 58 are parts of stationary terminal assemblies which will be described in greater detail presently. As the lever 20 is released, the rotary contact device remains stationary while the spring 48 restores the pawl 48 and lever 20 to their initial positions as shown in Fig. 2.

As shown best in Figs. 2 and 6, one end of each contact spring 58 is anchored securely to a terminal 80, preferably by being permanently bonded to one end of such terminal. The intermediate portion of each contact spring 58 has a loop in it, and arcuate recesses 82 are formed in the flanged edged portions of the housing members I2 to accommodate these loops. The free ends of the contact springs 58 .are constantly engaging the periphery of the bridging contact member 48, thereby exerting a counter-thrust against each terminal 60. When the springs 58 are engaging a pair of contact-carrying teeth of the member 48, a direct electrical connection is established between the springs 58. In the present embodiment, there are four contact-carrying teeth and four insulating teeth on the member 48.

As mentioned above, one of the important features of this invention is the arrangement for retaining the terminals 68 securely in position without requiring that any portions of the terminal extend through the housing Ill. As best shown in Fig. 6, each terminal 60 is approximately I-shaped. The terminals 80 are stamped out of flat metallic stock such as brass, and the I configuration is imparted thereto by punching out wings or nibs 64 in the middle of the upper and lower edges of each terminal. 'The nibs 54 are clinched over the end of an external electrical conductor 65 for connecting this conductor electrically and mechanically to the terminal 50. The terminals 80 are disposed within the hollow interior of the housing III, and the extended marginal portions of each terminal 80 are received in corresponding recesses 68 afforded between the legs of H-shaped projections or bosses III on the inside faces of the housing members I2. The bosses 10, in the present embodiment, are integral parts of the housing members I2. The cross ribs 12 of the bosses I are received in the corresponding punched-out notches or recesses 14 in the terminals 68.

When the switch is being assembled. the terminals 60 are positioned in cooperative relation with the bosses 18 as indicated in Figs. 2 and 4. Clearance openings 18, Figs. 5 and 6, in the housing members I2 permit the passage of the electrical conductors 68 which are connected to the terminals 60. It is evident that when the housing ing parts of the switch are exposed through the housing.

This manner of retaining the terminals 68 within the housing I 0 afiords a considerable saving in space. In a commercial embodiment of this invention, the thickness or depth" of the unit (that is, the distance between the outer faces of the housing members I2) is .5 3 of an inch. In the prior art construction, where the terminals had projections that were extended through the insulating support plates, it was necessary to enclose the entire unit by an outer housing or case which added of an inch to the depth of the unit, making the total depth is of an inch. The present switch, being more shallow by a of an inch than the prior switch, enables this form of switch to be used in a great many new situations. Although the principles of the invention have been shown embodied in a single-circuit switch, they can be-applied alsoto switches capable of handling more than one circuit. The presentday trend in the construction of lighting fixtures, electric fans and other appliances is to allow less space for the accommodation of a switch than has been done formerly. The present invention provides a switch which will meet this need withoutany reduction in the current-carrying capacity of the switch.

As seen best in Fig. 4, the legs of the retaining bosses 10 have very limited transverse dimensions, so that they do not interfere with the yielding movements of the stationarily mounted contact springs 58. That is to say, these legs are quite thin and narrow, and there is ample clearance for the springs 58 as they move back and forth. There is also adequate space to accommodate the nibs 84 and wires 86 on the outer sides of the terminals 80. It should be understood that' retaining projections or shouldered portions having other configurations may be utilized in place of the H-shaped bosses ID, and the shape of the terminals 60 may be correspondingly varied, so lon as the operating parts of the switch are accommodated within the limited space allowed. Not only is it desirable that the thickness of the switch be no greater than that of the preassembled unit alone in the prior switch /32 inch) but also that the distance between the terminals 60 should be no greater than formerly (approximately V inch). The particular configurations illustrated herein are admirably suited for that purpose.

While the invention has been described with reference to a preferred embodiment thereof, modifications of such embodiment may be possible without departing from the principles set forth above, and it is intended that all such modifications shall be included within the scope of the appended claims.

I claim:

1. In a switch of the type having electrically conductive current-carrying parts including a rotary contact device and stationary terminals with yieldable contact springs extending respectively from said terminals into engagement with the rotary contact device, the combination, with said terminals, of a housing for completely enascaaoo closing and supporting in an operating position the conductive current-carrying parts of the switch, such housing being composed of two identical complementary internally hollowed insulating members having edge portions disposed in mating engagement, said members defining a hollow within the housing for receiving the conductive current-carrying parts of the switch, said terminals being disposed in said hollow entirely within said housing, each of said insulating members having on the inside face thereof integral projections engageable with the edges of the terminals for holding the terminals in place, said projections and said terminals having complementary H-shaped and I-shaped configurations and each of said terminals having integral strap portions centrally thereof deformed to encircle conducting portions of a wire and physically retain the same thereon, with said strap portion of each terminal positioned at the central portion of the H-shaped projections.

2. In a switch of the type having electrically conductive current-carrying parts including a rotary contact device and stationary terminals with yieldable contact springs extending respectively from said terminals into engagement with the rotary contact device and flexing laterally in the switch, the combination, with said terminals, of a housing for completely enclosing and supporting in an operating position the conductive current-carrying parts of the switch, such housing being composed of two complementary identical internally hollowed insulating members having edge portions disposed in mating engagement. said members defining a hollow within the housing for receiving the conductivecurrent-carrying parts of the switch, said terminals each having a central restricted portion for gripping a wire thereon and being disposed in said hollow entirely within said housing, said insulating members having on their inside faces recessed and shouldered parts for receiving and holding the terminals at their edges, with a pair of recesses separated by a projecting shouldered part in each housing member for each terminal and adapted to have the central restricted portion of each terminal member at said projecting shouldered part, said shouldered parts having limited dimensions to aiford clearance for the contact springs so that such springs may flex in their operation thereof over at least a portion of the inner faces of the shouldered parts.

3. In a switch having a rotary contact device, the combination of a housing composed of two identical mating internally hollowed insulating members with apertures at one end thereof, stationary contact devices disposed entirely within the hollow interior of said housing, each device including a stationary terminal with a yieldable contact spring extending from one side of said terminal into engagement with the rotary contact device, said terminal having on its other side integral parts for gripping a wire conductor, a wire gripped in said integral part and extendin out through the apertures in the housing each of said insulating members having on the inside surface thereof integral projections for engaging and holding certain oppositely disposed edge portions of said terminals with said wire gripping integral part portions of said terminals positioned upon integral projections and intermediate said edge portions.

4. In an electrical switch having a pair of yieldable contacts, a rotary contact unit, and pull means for rotating the same, the combination of a stationary terminal member corresponding to each yieldable contact and supporting the same, each said member having a substantially rectangularly shaped body portion adapted to be retained at its side edges andh'aving a pair of straps on the body portion restricting the dimension of the body portion at the straps, and with said straps encircling and retaining a portion of a conducting wire therein with the wire extending longitudinally of the member and out 01' a housin for the switch. a

housing for the switch comprising a pair of identical cup-shaped molded insulating members entirely enclosing said rotary contact unit. said yieldable contacts, and said stationary members and supporting the same in operative relation, said members having complementary molded projections and recesses on the inside face thereof to position and retain the side edges of said terminal members, and mounting means for the switch having a portion within the housing and upset projections thereon gripping the two insulating members and securing them together to maintain the entire switch in an assembled condition.

5. In an electrical switch having switch mechanism with a plurality of stationary terminal portions, the combination including a housing for said mechanism having two identical complementary hollowed members constructed of molded insulating material, said hollowed members having edges disposed in mating engagement and defining a cavity supporting said switch mechanism, with said hollowed members completely insulatingly enclosing said terminal portions, integral H-shaped projecting portions on the inside of each hollowed member and formed on opposite sides of said cavity, said stationary terminal portions each being substantially I-shaped and having an edge portion on each side of a shape to lit in a corresponding H- shaped projecting portion, means on each terminal portion at the longitudinal central part thereof for holding a lead-in wire thereon, and said edges of said hollowed members having apertures therein aligned with said central parts for accommodating lead-in wires from said terminal portions.

RUDOLF POPP.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 1,410,651 Caps Mar. 28, 1922 2,051,925 Wertzheiser Aug. 25, 1936 2,156,902 Popp May 2, 1939 2,368,679 Popp Feb. 6, 1945 2,439,947 Pontius Apr. 20, 1948 2,477,387 Mestitz July 30, 1949 2,486,033 Kaminky Oct. 25, 1949 

